Masonry structure

ABSTRACT

A factory-build masonry fireplace includes a firebox, casing, and chimney system, where the firebox defines a cavity. Masonry panels are removably attached to the periphery of the cavity. Each masonry panel has firebrick housings configured to hold a corresponding firebrick, wherein the housings can optionally be arranged in a running bond and herringbone patterns, among others. Additionally, the base masonry panel defines an opening configured to hold a removable ash dump, the opening covered with a removable cover. In another arrangement, masonry panels have protruding walls that are configured to hold a corresponding firebrick. The masonry panels are used to build traditionally site built masonry structures.

RELATED APPLICATIONS

This application relates to and claims the benefit of the provisionalapplication 60/452,478, filed Mar. 5, 2003, which is hereby incorporatedby reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to masonry, and in particular tofactory built masonry.

2. Description of the Related Art

Masonry structures have are well known in the art and have existed formany years. Many traditionally site built masonry structures (e.g.,fireplaces, countertops, brick walls, and the like) may have to beconstructed by a mason and thus can be expensive. Traditional site builtmasonry structures can also require significant installation time. Forexample, site built masonry fireplaces commonly found in residentialstructures and can be expensive and require substantial installationtime.

Over the years, factory built fireplaces have grown in popularity due tothe increased cost of site constructed masonry structures. Additionally,building code restrictions in some localities limit or altogetherprohibit the use of masonry chimneys, making the use of factory builtfireplaces desirable in these localities. Moreover, factory builtfireplaces are capable of being installed in multi-level buildings,where construction of traditional masonry units is not feasible.

Even where the construction of masonry fireplaces is feasible,construction usually requires a significant amount of time and costs,significantly more than a factory-built fireplace. Additionally,installation of tradition masonry fireplaces generally requires theservices of a licensed mason or other construction professional, addingto the cost of construction.

Throughout the development of the factory-built fireplace industry,designers have sought to design fireplaces to resemble traditionalmasonry built fireplaces. For example, recent designs of factory-builtfireplaces have incorporated refractory panels to better resemble amasonry fireplace. However, such refractory panels, and other similardesigns, have been incapable of achieving the desired masonry look. Inanother example, bricks have been added to the firebox area of afireplace in an attempt to create a masonry look. However, suchconstruction design has proved structurally unstable, often falling andbreaking, and thus unable to provide adequate retention of bricks.Additionally, such designs have provided poor alignment of bricks andhave not been capable of providing multiple brick pattern arrangements.

The desire for factory-built fireplaces that resemble masonry fireplacesis particularly strong among owners and builders of high-end homes, whoprefer the traditional look of masonry fireplaces. However, as notedabove, some localities restrict or prohibit the use of masonryfireplaces due to, for example, the risk of seismic activity in thelocality. Thus, there is a need for factory built masonry structuresthat resemble site built masonry.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the invention disclosed herein,panels can comprise a backing and a plurality of walls attached to thebacking. The walls can have holding members configured to hold a body,such as a brick or tile. The holding members of the walls cooperate toreceive and hold firebricks. The holding members can be tabs that extendfrom the walls of the panels. The walls having the holding members canbe generally perpendicular to the panels. The panels can beprefabricated panels used to build traditionally site built masonrystructures. The site built masonry structures can be, e.g., fireplaces,countertops, brick walls, or hearths.

In accordance with one embodiment of the invention disclosed herein, afactory-built fireplace is designed to look like a traditional masonryfireplace. The fireplace comprises a firebox having an inner cavity anda chimney system. The cavity preferably comprises a frame comprisingrails or panels that define the periphery of the cavity. The framedefines side areas, a rear area, a base area and a top opening in thefirebox, wherein the opening is preferably connected to the chimneysystem. In addition, the fireplace includes masonry panels configured tobe installed on the side areas, rear area and base area of the cavityframe.

The masonry panels are preferably made of a metallic material, such assteel. However, the panels can be made of any material providing thenecessary structural, thermal, and other characteristics required infireplace construction. Also, the panels are preferably sized to coversubstantially the entire side, rear and base areas of the cavity frame.Additionally, the panels preferably have a thickness capable ofproviding adequate structural support to the masonry material installedthereon.

The panel disposed over the base of the firebox cavity optionallydefines an opening therethrough. The opening is preferably disposed neara front edge of the base of the firebox, wherein the front edge of thebase is near the front end of the firebox. Additionally, a removablecover can optionally be disposed over the opening. The opening ispreferably sized to receive a removable ash dump, which is capable ofreceiving ashes produced during the burning of logs or other material inthe fireplace. The ash dump is preferably configured to be easilyremoved from the opening and to be easily emptied. The cover and the ashdump are preferably configured to be removed and replaced without theuse of any tools.

The fireplace also includes a plurality of firebrick housings configuredto be installed on the masonry panels. For example, the housings can bebolted, screwed, riveted, or welded to the panels. The firebrickhousings can optionally be attached to the panels so that they arearranged in a running bond, a herringbone pattern, or other decorativepattern. The housings are preferably disposed such that a gap is betweenadjacent housings. Optionally, the housings can be disposed so thatthere is no gap between adjacent housings.

The firebrick housings are preferably sized to receive a firebrickthereon. However, the housings can optionally be configured to receiveany material suitable for use in a fireplace or other high-temperatureenvironment. Additionally, the housings preferably comprise at least oneholding member configured to adequately hold a firebrick in the housing.In one embodiment, for example, the holding member is a structure thatextends from the wall of the housing. The extending structure isadvantageously configured to engage with at least one groove in thefirebrick. In another example, the holding member is a plurality ofprotuberances extending outward from the surface of the housing,configured to receive mortar around the protuberances, and to adhere toa firebrick disposed thereon. In still another example, the housing canbe configured to receive and hold a firebrick without the use of mortaror other adhering material. Additionally, mortar is preferablyintroduced into the gaps disposed between the housings to achieve thelook of a traditional masonry fireplace.

The firebricks of the masonry panels are configured to be coupled to thepanels. Preferably, the panels have firebrick housings configured toreceive and hold firebricks. A portion of the firebrick is preferably ofsimilar shape as a portion of the housing. For example, both thefirebrick and housing can be generally rectangular. In one embodiment,the firebrick comprises the pair of sides, each side having a channel orgroove that is configured to receive a portion of the holding member.The channel or groove can have a generally U-shaped or similarcross-section. The groove can extend along a portion of the firebrick.In another embodiment, the groove extends from one side of the firebrickto an opposing side of the firebrick. The masonry panel can comprisebricks having grooves and some bricks without grooves.

In accordance with another embodiment, factory-built masonry structuresare able to be constructed at significantly less cost than traditionalmasonry structures. The masonry panels are preferably constructed suchthat the costly layout of the brick pattern is eliminated. Additionally,individual brick housings are preferably incorporated into the panel toadvantageously allow fast and accurate construction. For example, thepanels can be constructed having the firebrick housings pre-arranged ina specific pattern, such as running bond or herringbone. Moreover, thefirebricks supplied with the fireplace are preferably pre-cut andidentified as corresponding to a particular housing, advantageouslyreducing the time, and thus the cost, of construction. For example, thefireplace can be constructed by an individual who may not normally haveexpert masonry skills, again reducing the construction costs. Forexample, the fireplace can be constructed by a certified fireplaceinstaller or a homeowner Accordingly, a factory-built masonry fireplacecan be constructed to resemble a traditional masonry fireplace at lessthan 20% of the cost and significant savings in installation time.

In accordance with another embodiment, the necessary materials forconstructing a factory-built masonry fireplace are provided in a kit.The kit preferably comprises a firebox defining a cavity with a frame,the frame having side areas, a rear area, a base area, and a topopening. The kit also comprises a chimney system, wherein the chimneysystem connects to the top opening of the cavity frame. The kit alsocomprises a plurality of masonry panels preferably configured to beremovably attached to the side areas, rear area and base area of thecavity frame. A plurality of firebrick housings is preferably attachedto the masonry panels. Additionally, a plurality of preferably pre-cutfirebricks is provided, wherein the firebricks preferably correspond tothe plurality of housings. The kit also comprises an amount ofhigh-temperature cement.

The kit enables the user to easily install the plurality of firebrickhousings onto the masonry panels and arrange the housings in a desiredpattern, such as running bond or herringbone. Alternatively, thehousings can be pre-installed and arranged at a factory prior todelivery of the kit to the user. The user then installs the masonrypanels on the side areas, rear area, and base area of the cavity frame.Optionally, the masonry panels and the cavity frame are assembled andpre-installed at the factory. The user can mix the high-temperaturecement to prepare mortar material. The user can place the bricks intothe housings of the panel, where the firebrick preferably corresponds tothe housing. The user can repeat this process with the remainingfirebrick housings. Once the user has installed the plurality offirebricks in the plurality of housings, the user can apply mortarmaterial into any gaps between any adjacent firebricks to grout thefirebrick assembly. The user can then allow the masonry fireplace curefor a desired amount of time before use. Once the masonry fireplace isproperly cured, the user can optionally install a facade around thefireplace, as desired. The facade can be formed of masonry panels havinghousing configured to receive and hold firebricks. Firebricks can becoupled to the masonry panels to achieve a site built masonryappearance.

Other objects, advantages, and features of embodiments of the presentinvention will become readily apparent to those skilled in this art fromthe ensuing detailed description of preferred embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an elevated frontal view of a factory-built fireplace havingmasonry panels installed therein.

FIG. 1B is a side view of the fireplace of FIG. 1A.

FIG. 2A is an exploded view of the fireplace illustrated in FIG. 1Aillustrating the masonry panels installed on the rear wall, sidewallsand base of the fireplace cavity.

FIG. 2B is a top view of a masonry panel for the base of the fireplacehaving a herringbone pattern.

FIG. 3A is a top view of a masonry panel for the base of the fireplace,illustrating the firebrick housings thereon.

FIG. 3B is a perspective view of a masonry panel for the fireplace.

FIG. 4 is a top view of a firebrick housing configured to receive afirebrick.

FIG. 5 is a sectional view of the firebrick housing of FIG. 4 along line5-5.

FIG. 6A is a top view of a firebrick housing in accordance with anotherembodiment.

FIG. 6B is a side view of the firebrick housing of FIG. 6A.

FIG. 7 is a top view of a firebrick housing in accordance with anotherembodiment.

FIG. 8 is a sectional view of the firebrick housing of FIG. 7 along line8-8.

FIG. 9A is a top view of a firebrick housing in accordance with anotherembodiment.

FIG. 9B is a side view of the firebrick housing of FIG. 9A

FIG. 10A is a top view of a firebrick housing having protuberances.

FIG. 10B is a side view of the firebrick housing of FIG. 10A.

FIG. 11A is a perspective view of a firebrick housing.

FIG. 11B is a perspective view of a firebrick configured to fit in thehousing of FIG. 11A.

FIG. 12A is a perspective view of a firebrick housing.

FIG. 12B is a perspective view of a firebrick configured to fit in thehousing of FIG. 12A.

FIG. 13 is a perspective view of a firebrick having a pair of grooves.

FIG. 14 is a side view of the firebrick of FIG. 13.

FIG. 15 is an exploded sectional view of a masonry panel for the base ofthe fireplace illustrating an ash dump.

FIG. 16 is an elevated frontal view of a factory-built fireplace havingmasonry panels in accordance with another embodiment.

FIG. 17 is a perspective view of a masonry storage box.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIGS. 1A and 1B, a factory-built masonry fireplace 100is illustrated therein. The fireplace 100 generally comprises a firebox10 having a front end 12 and a rear end 14. The firebox 10 defines acavity 30 and panels 40 b, 50 b, 60 b are preferably disposed in thecavity 30. In the illustrated embodiment, the fireplace 100 has achimney outlet 20, which is part of a chimney system (not shown).However, the furnace 100 can be vent free, thus not requiring a chimneysystem. The fireplace 100 can be adapted to burn various types ofmaterials. For example, the fireplace 100 can be a wood and/or gasburning fireplace.

FIG. 2A illustrates the fireplace 100 of FIG. 1A with the panels 40 b,50 b, 60 b removed. The cavity 30 has a frame (not shown) with a reararea 40 a, side areas 50 a and a base area 60 a. The frame can compriseat least one rail that defines the periphery of the cavity 30. The framecan optionally comprise a plurality of panels, such as a rear wall 40 a,sidewalls 50 a and a base 60 a. Optionally, the panels 40 b, 50 b, 60 bcan comprise the frame areas 40 a, 50 a, 60 a.

The panels 40 b, 50 b, 60 b are preferably removably attached to therear area 40 a, side areas 50 a, and base area 60 a, respectively. Forexample, the panels 40 b, 50 b, 60 b can be riveted, bolted, screwed,welded, or connected with other connectors or fasteners to the cavityframe areas 40 a, 50 a, 60 a. In the illustrated embodiment, the panels40 b, 50 b, 60 b are in the form of masonry panels configured to receivea body, such as a firebrick.

The panels 40 b, 50 b, 60 b are preferably made of metal. For example,the panels 40 b, 50 b, 60 b can be made of steel. Optionally, the panels40 b, 50 b, 60 b can be made of a sheet metal commonly used in thefireplace industry. However, the panels 40 b, 50 b, 60 b can optionallybe made of any material providing the necessary structural, thermal, andother characteristics required in fireplace construction.

The panels 40 b, 50 b, 60 b are preferably sized to cover substantiallythe entire frame areas 40 a, 50 a, 60 a, respectively. Additionally, thepanels 40 b, 50 b, 60 b are preferably configured to provide adequatestructural support to masonry material disposed thereon. For example,the panels 40 b, 50 b, 60 b can have a thickness capable of providingsaid structural support.

According to the illustrated embodiment, the panels 40 b, 50 b, 60 bcomprise a running bond pattern. However, the panels 40 b, 50 b, 60 bcan comprise other patterns, such as a herringbone pattern, asillustrated in FIG. 23.

FIG. 3A illustrates a panel 60 b in the form of a masonry panel for thebase of the fireplace 100. The panel 60 b is configured to receive andhold a plurality of firebricks. According to the illustrated embodiment,a plurality of templates or firebrick housings 70 is preferablyremovably attached to the panel 60 b. It should be understood that thefirebrick housings 70 can be similarly arranged on the panels 40 b, 50 bdisposed on the rear area 40 a and side areas 50 a of the firebox cavity30.

In the illustrated embodiment, the plurality of housings 70 are alignedin a running bond pattern. However, the housings 70 may be arranged inother patterns, such as a herringbone pattern. Additionally, accordingto the illustrated embodiment, the housings 70 are preferably aligned ina row with no gap between the ends of the housings 70. Also, thehousings 70 are disposed such that there is a gap between the rows ofhousings 70. Optionally, the housings 70 can be arranged so that thereis a gap between the housings 70 forming a row. Also, the housings 70can optionally be arranged so there is no gap between the rows ofhousings 70.

The housings 70 are preferably attached to the masonry panels 40 b, 50b, 60 b with readily available connectors and fasteners (not shown),such as bolts, screws, rivets or welds.

FIG. 3B illustrates a panel 60 b for the base of the fireplace 100. Thepanel 60 b is configured to receive and hold at least one brick. In theillustrated embodiment, the plurality of firebrick housings 70 areattached to the panel 60 b and are aligned in a herringbone pattern.There can be gaps 102 between the sides or the ends of the housings 70.Optionally, in some embodiments, there may be no gaps between thehousings 70. Although not illustrated, the panel 60 b and the housings70 can be integrally formed.

At the periphery of the panel 60 b are edges 104, each edge having aplurality of openings or holes 106 that are used to couple the masonrypanel 60 b to the fireplace 100. According to the illustratedembodiment, the edges 104 comprise a flat body having openings 106configured to receive a screw, fastener, or other suitable device forattaching the panel 60 b to the fireplace 100. Thus, to install themasonry panel 60 b, the panel 60 b can be placed in the desired locationin the fireplace 100 and fasteners can be passed through the openings106 to secure the panel 60 b to the fireplace.

The housings 70 are preferably attached to the masonry panel 60 b bypassing fasteners through at least one opening or hole 108 in each ofthe housings 70. In the illustrated embodiment, the housings 70 areattached to a backing of the panel 60 b and the backing of the panel 60b can be sheet metal or other suitable structure for holding thehousings 70 which in turn hold firebricks. In one embodiment, each ofthe housings 70 has a plurality of holes 108 to ensure that the housingsremain attached to masonry panel 60 b when bricks are disposed and heldwithin the housings 70. Although not illustrated in FIG. 3B, firebrickscan be installed in the housings 70 as discussed below.

The panel 60 b in the illustrated embodiment is generally flat. However,the panel 60 b can have other shapes. For example, the panel 60 b canpreferably comprise at least one flat portion and at least one curvedportion. In one embodiment, at least a substantial portion of the panel60 b is curved. Those skilled in the art recognize that there arevarious shapes and configurations to achieve a desired appearance ofmasonry panel.

FIG. 4 is a top view of the firebrick housing 70. The housing 70 isadapted to be attached to a structure and hold a body. The housing 70can have at least one sidewall 110 and a base 112. The sidewall 110 andbase 112 may cooperate to define a cavity 114, which is preferablyconfigured and sized to receive a firebrick. In the illustratedembodiment, the housing 70 comprises a pair of sidewalls 110. In anotherembodiment not illustrated, the housing 70 comprises one sidewall 110and the base 112 forming a generally L-shape bracket.

Each sidewall 110 has an inner surface 116 and a holding member 78 a.The inner surface 116 defines a portion of the cavity 114. The sidewall110 has at least one holding member 78 a that is configured to engagewith a firebrick to hold at least a portion of a firebrick within thehousing 70. The holding member 78 a has a longitudinal surface or edge79 that can engage with the firebrick. However, the holding member 78 acan have any shape that can engage with the firebricks. Optionally, thesidewall 110 can have a plurality of holding members 78 a, asillustrated in FIG. 4. The holding member 78 a can extend from at leastone side of the wall 110. In one embodiment, for example, the housing 70has a pair of sidewalls 110, each sidewall 110 has a pair of holdingmembers 78 a. The holding members 78 a extend from the inner surface 116and into the cavity 114. Thus, a plurality of holding members 78 aextend from the walls 110 for engaging the firebrick. The holdingmembers 78 a can be disposed at various locations along the sidewall 110to ensure that the firebrick is securely held in the housing 70.

The base 112 has several holes 108 that can be used to attach thehousing 70 to the panel, such as masonry panel 60 b. However, the base112 can optionally be welded or attached to the panel 60 b in any othersuitable manner so that the housing 70 can hold a firebrick. In theillustrated embodiment, the base 112 has a generally rectangular shapeand is attached to the pair of sidewalls 110. The base 112 has a pair ofopposing side edges that are attached to the bottom edge of thesidewalls 110 and defines the bottom of the cavity 114.

The cavity 114 is preferably similar in shape to at least a portion thefirebrick which is pre-cut to be received in the cavity 114. In theillustrated embodiment, the cavity 114 is generally rectangular andconfigured to receive a similarly shaped firebrick. However, the cavity114 can be any other suitable shape and size for receiving a firebrick.

FIG. 5 is a cross-sectional view of the housing 70 shown in FIG. 4 alongline 5-5. A portion of the firebrick 120 (shown in phantom) is showndisposed within the cavity 114. The holding members 78 a are located oneither side of the firebrick 120 and engage with grooves 122 in thefirebrick 120.

The firebrick 120 is preferably configured to engage with at least oneof the holding members 78 a to ensure that the firebrick 120 remains inthe panel 60 b. In one embodiment, the firebrick 120 has at least onegroove 122 along a side 124 of the firebrick 120. The groove 122 issized for receiving the end portion 125 of the holding member 78 a tolimit the movement of the firebrick 120. Preferably, at least a portionof the edge 79 is disposed within the groove 122. Optionally, thefirebrick 120 can comprise a pair of sides 124 and a plurality ofgrooves 122. The firebrick 120 can have the groove 122 along one side124 and another groove 122 along another side 124. In the illustratedembodiment, for example, the firebrick 120 is generally rectangular andhas a pair of sides 124 that are generally parallel and rectangular,each side 124 having the groove 122.

The holding member 78 a in the form of a flange or tab can extend fromthe wall 110 and engage with the firebrick 120. The holding member 78 ahas one side connected to the wall 110 and another side having the end125. As shown in FIGS. 3B and 5, an opening 126 is defined by theholding member 78 a and the wall 110. The holding member 78 a can have agenerally curved cross-section, straight cross-section, or any othersuitable shape to hold the firebrick in the housing 70. In theillustrated embodiment, the holding member 78 a has a cross-section thathas a curved portion and straight end portion. The member 78 a can havea generally uniform thickness. Those skilled in the art recognize thatthe member 78 a can have a non-uniform thickness. The member 78 a, forexample, can have a thickness that is reduced towards the end 125.

The holding member 78 a has the end 125 that is configured and sized tofit in a portion of the firebrick 120 to thereby hold the firebrick 120.In the illustrated embodiment, the end 125 of the holding member 78 a ispreferably configured to fit within the groove 122 of the firebrick 120.However, the end 125 may be configured to fit within a hole or otherstructure in the firebrick 120 for holding the firebrick.

The grooves 122 and the holding members 78 a can be arranged so that thebottom of the firebrick 120 engages with the base 112. The base 112 caninhibit the movement of the firebrick 120. However, the grooves 122 andthe holding members 78 a can be arranged so that the bottom of thefirebrick 120 and the base 112 are spaced apart so that a cement mixturecan be received in the gap between the firebrick 120 and the base 112.Further, the firebrick 120 and base 112 can be spaced apart so that atleast one of the holding members 78 b, 78 c (described below) aredisposed between the firebrick and the base.

FIG. 6A and FIG. 6B illustrate the firebrick housing. The housing 70preferably has at least one sidewall 110 having a plurality of holdingmembers 78 a, where at least one holding member 78 a is located oneither side of the wall 110.

In the illustrated embodiment, the housing 70 comprises the pair ofwalls 110. A first holding member 78 a is disposed on one side of thewall 110 and a second holding member 78 a is disposed on the other sideof the wall 110. The walls 110 are spaced apart and configured toreceive the firebrick 120 within the cavity 114 and engage with at leastone firebrick 120 a, which is exterior the housing 70. In other words,the wall 110 engages with the firebricks located on either side of thewall 110. As in the illustrated embodiment, each sidewall 110 has a pairof holding member 78 a, each holding member 78 a engages the groove ofthe firebrick. Although not illustrated, the wall 110 can have aplurality of holding members 78 a located on one side of the wall 110and a plurality of holding member 78 a located on the other side of thewall 110.

Gaps 102 can be formed between adjacent firebricks 120 as shown in FIG.6B. Cement mixture can be disposed in the gaps 102 to further ensurethat the firebricks 120 remain in the masonry panel 60 b. Optionally,the cement mixture can be placed within voids between the firebricks120, 120 a and the housing 70 to ensure that the firebricks remainsecurely attached to a masonry panel 60 b. Thus, the holding member 78 ain combination with a cement mixture ensure that the firebricks 120, 120a remain securely coupled to the firebrick housings 70. The housing 70can comprise a variety of different holding members. For example, thehousing 70 can have at least two of the holding members that incombination hold the firebrick 120.

FIG. 7 illustrates a firebrick housing 70 that is generally similar tothe housing 70 of FIG. 6. The firebrick housing 70 has a plurality ofholding members 78 a extending into the cavity 114 configured to engagea firebrick. The housing 70 can have a lip or flange 113 at its upperand lower ends for engaging the ends of the firebrick. The flanges 113can inhibit movement of the firebrick which is captured by the housing70. Thus, the holding members 78 a and flanges 113 cooperate to ensurethat the firebrick remains securely held in the housing 70. In theillustrated embodiment, the holding members 78 a prevent the firebrickfrom being moved away from the base 112 and the flange 113 prevents thefirebrick from sliding along the longitudinal axis of the housing 70.Although not illustrated, there are other suitable structures that canprevent undesirable movement of the firebrick disposed within thehousing 70.

With respect to FIG. 8, the holding members 78 a are located on eachside of the firebrick, shown in phantom. In the illustrated embodiment,the holding member 78 a is in a form of flange or tab. The tab 78 a isgenerally straight and extends at an angle from the wall 110. The end125 of the tab 78 a is preferably adapted to engage with grooves 122 tohold the firebrick. When the brick 120 is held by the housing 70,flexible walls 110 of the housing 70 can contact and tightly grip thesides 124 of the brick 120. Further, the bottom of the brick 120preferably contact the upper surface of the base 112 to reduce movementof the brick 120 relative to the housing 70.

FIG. 9A and FIG. 9B illustrate a firebrick housing. The housing 70preferably comprises at least one sidewall 72 and a base 74 defining acavity 76. In one embodiment, the housing 70 has at least two sidewalls72 extending from the base 74 and defining the cavity 76, which isgenerally rectangular in shape and is preferably configured to receive afirebrick. However, the housing 70 is not limited to having at least twosidewalls 72. In another embodiment, the housing 70 comprises a singlesidewall 72. The sidewall 72 can be formed of metal or other suitablematerial for holding firebricks.

The cavity 76 is preferably configured to receive a pre-cut firebrick.However, the cavity 76 can optionally be configured to receive a brickthat is not pre-cut. In another option, the cavity 76 can be configuredto receive any material suitable for use in a fireplace or otherhigh-temperature environment. In the illustrated embodiment, the base 74of the housing 70 has a generally rectangular shape. However, the base74 is not limited to a rectangular shape and can comprise other shapesconfigured to receive a firebrick of generally similar shape.

In the illustrated embodiment, a holding member 78 b is preferablydisposed on the base 74 of the firebrick housing 70. The holding member78 b can optionally be removably attached to the base 74 of the housing70 using any number of connectors or fasteners, such as screws orrivets. In another option, the holding member 78 b can be welded to thebase 74 of the housing 70.

The holding member 78 b is preferably configured to hold a firebrick inthe housing 70 in combination with mortar material. In the illustratedembodiment, the holding member 78 b is a wire mesh. However, the holdingmember 78 b can comprise any structure capable of holding a firebrick onthe housing 70. For example, the holding member can comprise a pluralityof protuberances 78 c, as illustrated in FIGS. 10A and 10B. In anotherexample, the at least one sidewall 72 can comprise the holding member.

With continued reference to FIG. 9B, a fastener in the form of a rivotor bolt 75 passes through the base 74 and can connect the housing 70 tothe panel 60 b. A head of the bolt 75 is located between the wire mesh78 b and the base 74. However, the bolt 75 can be located in anysuitable position for coupling the housing 70 to the base 74.Optionally, a plurality of fasteners 75 can be used to attach thehousing 70 to the panel 60 b.

FIG. 11A illustrates a firebrick housing 71 having the sidewall 110around a portion of its periphery. The housing 71 has the pair of holes108 for coupling the housing to the masonry panel 60 b.

The side wall 110 comprises a pair of generally flat bodies at an angleto each other. The walls 110 are configured to engage with a portion ofa firebrick. The walls 110 can inhibit movement of the firebrick 120disposed within the housing 71. Although not illustrated, housing 71 cancomprise a holding member to ensure that the firebrick remains attachedto the masonry panel 60 b.

FIG. 11B illustrates a firebrick configured to engage with the housing71 of FIG. 11A. The firebrick 123 is sized and shaped so that a portionof the firebrick 123 fits within the cavity 114 of the housing 71. Inthe illustrated embodiment, the firebrick 123 has a pair of sides 125that can contact the sides 110 of the housing 71 to inhibit movement ofthe firebrick 123.

FIG. 12A illustrates another embodiment of a firebrick housing. Thehousing 73 has a sidewall 110 around a portion of its periphery. Thebase 112 of the housing 73 is generally triangular and configured tohold a firebrick of generally similar shape. The sidewalls 110 canengage with the outer surfaces 127 of the firebrick 129 (shown in FIG.12B) disposed within the housing 73 to ensure proper alignment of thefirebrick.

With reference to FIG. 3B, a variety of different shaped housings can beused to form the panel 60 b. For example, housings 70, 71, 73, inaddition to other shaped housings, can be used to form the herringbonepattern or other desired pattern. Some of the housings can comprise aholding member to ensure that the firebricks remain properly secured inthe masonry panel 60 b. The housing 70 can comprise a variety ofdifferent holding members, such as holding members 78 a, 78 b, 78 c. Itis contemplated that those skilled in the art can determine theappropriate type and sized of housing and holding members for a desiredpattern of firebricks, structural properties of the panel, and the like.A further advantage is provided where the housings 70 have holes orapertures so that the housings can be conveniently and quickly coupledto masonry panels 60 b either on site or in the factory.

FIG. 13 is perspective view of the firebrick 120 similar to thefirebrick of FIG. 5. As discussed above, the firebrick 120 is configuredto fit within the cavity 114 of the housing, such as housing 70. Aportion of the firebrick 120 is preferably of similar shape as a portionof the housing 70.

In the illustrated embodiment, the firebrick 120 comprises the pair ofsides 124, each side 124 having the channel or groove 122. The groove122 is generally U-shaped. However, the groove 122 is not limited to aU-shape and can comprise other shapes configured to receive a portion ofthe holding member, such as holding member 78 a. In other embodimentsfor example, the groove 122 can be V-shaped.

The groove 122 can extend along a portion of the side 124 or along theentire length of the side 124. The groove 122 can have a longitudinalaxis that is generally parallel to the upper surface 130 and the lowersurface 132 of the firebrick 120. The groove 122, of course, can be atdifferent locations on the brick 120 depending on the configuration ofthe housing that the brick is attached to. Further, many of the bricks120 disposed in the masonry panel 60 b may not have any groove 122. Inother words, the panel 60 b can comprise bricks 120 having grooves 122and some bricks 120 without grooves.

The firebrick 120 can be coupled to the panel (e.g., the panel 60 b) byinserting the firebrick 120 into the cavity 114 of a housing (e.g., thehousing 70) so that the holding member 78 a contacts and presses againstthe firebrick 120 as the firebrick passes through the cavity 114. Theholding members 78 a are pushed away or towards the sidewalls 110 as thebrick 120 is inserted into the cavity 114. When the firebrick 120reaches the desired position, the ends 125 of the holding member 78 amove into the groove 122, preferably when the bottom of the firebrick isnear the base 112, resulting in the firebrick 120 being held by thehousing. Thus, the firebrick 120 can be quickly and convenientlyinstalled or assembled by pushing the firebrick into the cavity 114 andagainst the base 112 and the members 78 a snap into the grooves 122thereby securing the brick in the fireplace 100. Thus, firebrick can beheld captive by the panel without the use or mortar or cement. Thefirebrick can be attached to the fireplace 100, as shown in FIG. 1A,without the use of cement.

Preferably, the firebrick 120 is held by the panel 60 b so that thefirebrick 120 cannot be pulled off of the panel 60 b. Thus, thefirebrick 120 can be permanently attached to the panel 60 b without theuse of cement or mortar. Optionally, the firebricks can be coupled tothe housings by sliding the ends 125 of the holding members 78 a intothe ends of grooves 122 of the brick. The ends 125 can then be slidealong the groove 122 until the brick reaches the desired position. Afurther advantage is provided where the firebricks can be pre-cut andidentified as corresponding to a particular housing, advantageouslyreducing the time, and thus the cost, of construction. In oneembodiment, the brick has indicia or markings that indicate acorresponding housing that is configured to receive that brick.

Cement or mortar can be used to achieve a traditional site built masonryappearance. For example, after bricks 120 are attached to the panel 60b, cement can fill in the spaces between the bricks 120 resulting in amasonry panel that has a traditional masonry appearance. The cement canprovide structural support to further ensure that the bricks 120 remainattached to the panels 60 b. Those skilled in the art recognize thatthere are various methods of attaching bricks 120 the panels andapplying cement to achieve the desired appearance.

As illustrated in FIGS. 2B, 3A, and 15 by the dashed lines, a cover 180is preferably removably disposed on the base masonry panel 60 b proximalto an edge 62 b, wherein upon installation of the panel 60 b in thefireplace 100, the edge 62 b is proximal to the front end 12 of thefireplace 100. The cover 180 is preferably configured to be easilyremoved from the panel 60 b without requiring any specific tools forremoval.

FIG. 15 illustrates an exploded sectional view of the base masonry panel60 b. The cover 180 is removably disposed over an opening 182 defined inthe base panel 60 b. In the illustrated embodiment, the cover 180 has aseveral bricks, or portions of bricks, that match the pattern of bricksformed by the panel 60 b. However, the cover 180 can have other surfacesand designs. Optionally, the cover 180 can have a handle 183 attached toits upper surface. The handle 183 can be used, for example, to move thecover 180 to expose the opening 182.

The opening 182 is preferably disposed proximal to an edge 62 b of thepanel 60 b, wherein the edge 62 b is proximal to the front end 12 of thefireplace 100 upon installation of the panel 60 b. Material, such aslogs, for burning can be located between the opening 182 and the masonrypanel 40 b. In the illustrated embodiment, the cover 180 and opening 182are rectangular in shape. However, the cover 180 and opening 182 are notlimited to this shape and can comprise other shapes, such as a square.

An ash dump 184 is preferably removably disposed in the opening 182 andconfigured to receive ashes produced by the burning of logs (not shown)in the fireplace 100. The ash dump 184 is preferably made of metal.Optionally, the ash dump 184 can be made of other materials having thenecessary fire resistant characteristics required for use in a fireplace100. Preferably, the ash dump 184 is configured to be easily removedfrom the opening 182. For example, the ash dump 184 can comprise handles184 a. In the illustrated embodiment, the generally rectangular ash dump184 comprises the pair of handles at its ends. The handles 184 a can besized and configured for convenient gripping. The ash dump 184 has anopening 186 at its upper end so that ash can pass through the opening186 and into the ash dump 184. Those skilled in the art recognize thatthe ash dump 184 can comprise any structure configured to allow easyremoval of the ash dump from the opening 182. However, the ash dump 184is not limited to this shape and can comprise a cross-section havingother shapes, such as a square. The ash dump 184 can be used incombination with panels as described herein.

A further advantage is provided where ashes can be conveniently removedfrom the cavity 30. Ashes are produced and accumulate on the masonrypanel 60 b as material (e.g., a wood log) burns in the fireplace 100. Inthe illustrated embodiment, the cover 180 can be manually removedexposing the opening 182 and the ash dump 184. Ash from the cavity 30can be conveniently swept through the opening 182 so that the ash fallsthrough the opening 186 and into the ash dump 184. Thus, ash producedfrom the burning of material can be removed from the cavity 30 andstored in the ash dump 184. The cover 180 can be replaced to cover theopening 182 for an attractive brick pattern defined by the panel 60 band the cover 180. These steps can be repeated to remove ashes withinthe cavity 30 for an attractive, ash free, fireplace 100. In oneembodiment, the material, such as wood logs, for burning can be locatedbetween the opening 182 and the masonry panel 40 b so that the cover 180can be removed and ash can be dumped in the ash dump 184 while the woodlogs conveniently remain in the cavity 30. The ash dump 184 canpreferably be removed from the fireplace 100 and emptied while the woodlogs remain in the cavity 30.

The ash within the ash dump 184 can be conveniently disposed of byremoving the cover 180 and exposing the ash dump 184. The ash dump 184can be pulled through the opening 182 and removed from the fireplace100, preferably without employing tools. The ash dump 184 can betransported to a garbage container (e.g., a trash can) and the ash fromthe ash dump 184 can be transferred to the garbage container. The emptyash dump 184 can be replaced in the fireplace 100 by passing the ashdump 184 through the opening 182. The cover 180 can be placed over theopening 182 and the ash dump 184, thereby hiding the ash dump 184underneath the cover 180 and the panel 60 b.

FIG. 16 illustrates another embodiment of a factory built masonryfireplace 100. The fireplace 100 is in the form of a gas fired fireplacethat is vent free.

The fireplace 100 can have panels defining at least a portion of itsface or facade. In one embodiment, the fireplace 100 comprises at leastone panel 200 that can be similar to the panels described herein. Thepanel 200 can define a portion of the opening of the cavity 30. In theillustrated embodiment, the fireplace 100 comprises an upper panel 200and a lower panel 202. The upper panel 200 defines the upper portion ofthe rectangular opening of the fireplace 100 and the lower panel 202defines the lower portion of the opening. Firebricks are advantageouslycoupled to the panels 200, 202 for site built masonry appearance.Optionally, the fireplace 100 can have a panel 206 at its lower end. Inthe illustrated embodiment, the panel 206 defines the hearth of thefireplace 100. Although not illustrated, masonry panels that are similarto the panels described herein can be used to form a mantel or otherportions of a fireplace.

In practice, the masonry fireplace 100 described above can beconstructed using a kit. The kit preferably comprises the firebox 10,the chimney system (not shown), and the panels 40 b, 50 b, 60 b,preferably preinstalled in the cavity 30 of the fireplace 100. Thepanels 40 b, 50 b, 60 b preferably have a plurality of firebrickhousings (e.g., housing 70) pre-installed thereon. The kit alsocomprises a plurality of firebricks, preferably pre-cut andcorresponding to the plurality of housings 70. The kit can also have anamount of a preferably high-temperature cement mixture.

A user mixes the high-temperature cement mixture, applies it to afirebrick housing 70 and disposes the corresponding firebrick in thehousing 70. For example, a user can apply the cement to a housing 70having a wire mesh 78 b or a plurality of protuberances 78 c such thatthe cement is disposed between openings in the wire mesh 78 b or aroundthe protuberances 78 c. Optionally, a user can dispose a brick in ahousing 70 configured to receive and hold a firebrick without theapplication of high-temperature cement or other mortar material. Theuser can then repeat this procedure with the remaining housings 70 toconstruct the masonry fireplace. Once the user has installed all thefirebricks in the corresponding housings, the user can apply thehigh-temperature cement material to any gaps between adjacent firebricksto grout the gaps. The methods of assembling the fireplace which aredescribed herein are not limited to the exact sequence of actsdescribed, nor is it necessarily limited to the practice of all of theacts set forth. Other sequences of events or acts, or less than all ofthe events, or simultaneous occurrence of the events, may be utilized inpracticing the disclosed embodiments. The panels can be used to achievesite built masonry appearance of indoor and outdoor structures. Forexample, the fireplace 100 can be can be outdoor fireplace.

The holding members described herein can be used to couple bricks tovarious types of structures. As illustrated in FIG. 17, the brick panelscan form a storage structure 210 in the form of a wood storing box. Thestructure 210 can be self standing or connected to another structure.For example, the panels can be similar to the panel 60 b and can form awood storing box that has an opening 212 for receiving at least aportion of wood logs. In one embodiment, the walls of the box are formedfrom panels similar to panels 60 b. In the illustrated embodiment, sidepanels 216 and a front panel 220 can form the vertical walls of the box210. Panel 224 forms the bottom of a chamber 225 which is configured toreceive wood logs. An upper surface or ceiling 226 defines the upperportion or the ceiling of the chamber 225 and the panel 228 forms theback of the chamber 225. In the illustrated embodiment, the top 232 ofthe box 210 is formed of cement. However, the top 232 or any otherportion of the box 210 can be formed of the panels described herein. Forexample, in another embodiment, the entire outer surface of thestructure 210 is formed by the panels configured to receive and holdbricks. Bricks can be placed into the panels such that holding membersand walls of the panels cooperate to hold the bricks. Thus, the bricksillustrated in FIG. 17 can be installed with or without the use ofcements. Cement, of course, can be applied between the bricks to groutthe panels to achieve site built masonry appearance. The storagestructure 210 can also be constructed from various types of metals andother materials with suitable characteristics such as plastics, wood, orcomposite materials. For example, the structure 210 can have a portionmade of wood and a portion made of metal. Preferably the bricks areattached to a panel that is similar to panel 60 b and substantially madeof metal. One of ordinary skill in the art can determine the appropriatecombination of material type, thickness, and shape to achieve thedesired structural characteristics.

The various embodiments disclosed herein can be used to form fire pits,brick walls, brick counters, and other structures that can be made ofbricks. For example, disclosed embodiments can form at least a portionof a countertop of an outdoor barbecue.

Although the inventions disclosed herein have been disclosed in thecontext of certain preferred embodiments and examples, it will beunderstood by those skilled in the art that the inventions disclosedherein extend beyond the specifically disclosed embodiments to otheralternative embodiments and/or uses of the inventions and obviousmodifications and equivalents thereof. Thus, it is intended that thescope of the inventions disclosed herein should not be limited by theparticular disclosed embodiments described above, but should bedetermined only by a fair reading of the embodiments that follow.

1-16. (canceled)
 17. A masonry structure comprising: a masonry panelconfigured to be removably attached to a wall of a firebox; and aplurality of brick housings, at least one of the brick housings having abase and a wall and a holding member extending from the wall, theholding member configured to engage with a brick.
 18. The masonrystructure of claim 17, wherein the base is attached to the masonry panelby at least one fastener.
 19. The masonry structure of claim 17, whereinsaid at least one of the brick housings comprises a second wall having aholding member, the first and second walls have an inner surface, and anouter surface, the inner surfaces define a portion of a cavity sized toreceive a brick, and the holding member comprises a tab extending intothe cavity.
 20. The masonry structure of claim 19, wherein the first andsecond walls are generally parallel.
 21. The masonry structure of claim17, wherein the holding member is a flange adapted to generally preventthe brick from being pulled out of said at least one of the brickhousings when the brick is disposed in that brick housing.
 22. Themasonry structure of claim 17, further comprising a brick having a pairof sides, at least one of the sides comprising a channel that isconfigured to engage with a portion of the holding member.
 23. Themasonry structure of claim 22, wherein the channel comprises a U-shapedchannel.
 24. The masonry structure of claim 18, wherein the panelcomprises a plurality of holes, and wherein said at least one of thebrick housings comprises a plurality of base holes on its base, the baseholes configured to be aligned with the holes on the panel, and said atleast one of the brick housings configured to be attached to the panelby said at least one fastener through the base and panel holes.
 25. Themasonry structure of claim 18, wherein said at least one fastenercomprises at least one of a bolt, screw, or rivet.
 26. The masonrystructure of claim 17, further comprising a grouting material betweenthe brick housings.
 27. The masonry structure of claim 17, wherein thepanel comprises a metallic material.
 28. The masonry structure of claim27, wherein the metallic material comprises steel.
 29. The masonrystructure of claim 17, wherein the brick housings are configured to beattached to the panel in a running bond pattern.
 30. The masonrystructure of claim 17, wherein the brick housings are configured to beattached to the panel in a herringbone pattern.
 31. The masonrystructure of claim 17, wherein the panel is configured to be removablyattached to a wall of firebox.
 32. An apparatus, comprising: a masonrypanel configured to be removably attached to a wall of a firebox; and aplurality of bricks attached to the panel.
 33. The apparatus of claim32, wherein the bricks are attached to the panel by a plurality of brickhousings, at least one of the brick housings having a base and a walland a holding member extending from the wall, the holding memberconfigured to engage with one of the bricks.
 34. The apparatus of claim33, wherein the base is attached to the masonry panel by at least onefastener.
 35. The apparatus of claim 33, wherein said at least one ofthe brick housings comprises a second wall having a holding member, thefirst and second walls have an inner surface and an outer surface, theinner surfaces define a portion of a cavity sized to receive a brick,and the holding member comprises a tab extending into the cavity. 36.The apparatus of claim 35, wherein the first and second walls aregenerally parallel.
 37. The apparatus of claim 33, wherein the holdingmember is a flange adapted to generally prevent the brick from beingpulled out of said at least one of the brick housings when the brick isdisposed in that brick housing.
 38. The apparatus of claim 33, furthercomprising a brick having a pair of sides, at least one of the sidescomprising a channel that is configured to engage with a portion of theholding member.
 39. The apparatus of claim 38, wherein the channelcomprises a U-shaped channel.
 40. The apparatus of claim 34, wherein thepanel comprises a plurality of holes, and wherein said at least one ofthe housings comprises a plurality of base holes in its base, the baseholes configured to be aligned with the panel holes on the panel, andsaid at least one of the housings configured to be attached to the panelby said at least one fastener through the base and panel holes.
 41. Theapparatus of claim 34, wherein said fastener comprises at least one of abolt, screw, or rivet.
 42. The apparatus of claim 32, further comprisinga grouting material between the bricks.
 43. The apparatus of claim 32,wherein the panel comprises a metallic material.
 44. The apparatus ofclaim 43, wherein the metallic material comprises steel.
 45. Theapparatus of claim 33, wherein the brick housings are configured to beattached to the panel in a running bond pattern.
 46. The apparatus ofclaim 33, wherein the brick housings are configured to be attached tothe panel in a herringbone pattern.
 47. An apparatus, comprising: afirebox having a plurality of areas; a plurality of masonry panels, eachof the masonry panels being configured to be removably attached to oneof the areas of the firebox; and a plurality of bricks attached to eachof the masonry panels.
 48. The apparatus of claim 47, wherein the bricksare attached to at least one of the panels by a plurality of brickhousings, at least one of the brick housings having a base and a walland a holding member extending from the wall, the holding memberconfigured to engage with one of the brick.
 49. The apparatus of claim48, wherein the base is attached to at least one of the masonry panelsby at least one fastener.
 50. The apparatus of claim 48, wherein said atleast one of the brick housings comprises a second wall having a holdingmember, the first and second walls have an inner surface and an outersurface, the inner surfaces define a portion of a cavity sized toreceive a brick, and the holding member comprises a tab extending intothe cavity.
 51. The apparatus of claim 50, wherein the first and secondwalls are generally parallel.
 52. The apparatus of claim 48, wherein theholding member is a flange adapted to generally prevent the brick frombeing pulled out of said at least one of the brick housings when thebrick is disposed in that brick housing.
 53. The apparatus of claim 48,further comprising a brick having a pair of sides, at least one of thesides comprising a channel that is configured to engage with a portionof the holding members.
 54. The apparatus of claim 53, wherein thechannel comprises a U-shaped channel.
 55. The apparatus of claim 49,wherein at least one the panels comprises a plurality of holes andwherein said at least one of the housings comprises a plurality of baseholes in its base, the base holes configured to be aligned with theholes on said at least one of the panels, and each of said at least oneof the housings configured to be attached to said at least one panel bysaid at least one fastener through the base and panel holes.
 56. Theapparatus of claim 49, wherein said fastener comprises at least one of abolt, screw, or rivet.
 57. The apparatus of claim 47, further comprisinga grouting material between the bricks.
 58. The apparatus of claim 47,wherein at least one of the panels comprises a metallic material. 59.The apparatus of claim 58, wherein the metallic material comprisessteel.
 60. The apparatus of claim 48, wherein the brick housings areconfigured to be attached to at least one of the panels in a runningbond pattern.
 61. The apparatus of claim 48, wherein the brick housingsare configured to be attached to at least one of the panels in aherringbone pattern.
 62. An apparatus comprising: a masonry panelconfigured to be removably attached to a wall of a firebox; and aplurality of housing members attached to the masonry panel, each of theplurality of housing members having a base, a first sidewall, and asecond sidewall, the first sidewall and the second sidewall extendingperpendicular from an edge of the base to form a cavity with the base,wherein each of the plurality of housing members is configured to housea brick in the cavity adjacent to the base between the first sidewalland the second sidewall.
 63. The apparatus of claim 62, wherein each ofthe plurality of housing members has at least one holding member. 64.The apparatus of claim 63, wherein the at least one holding member is awire mesh extending adjacent to the base within the cavity.
 65. Theapparatus of claim 63, wherein the at least one holding member comprisesa plurality of protuberances extending from the base, perpendicular tothe base and parallel to the first sidewall and the second sidewall. 66.The apparatus of claim 63, wherein the at least one holding membercomprises flanges extending from the first sidewall and the secondsidewall into the cavity.
 67. The apparatus of claim 62, furthercomprising: a plurality of bricks, each one of the plurality of bricksbeing inserted into a corresponding cavity of each of the plurality ofhousing members.